Method for producing hydrogen

ABSTRACT

The invention is a method for producing hydrogen using a generator, heating the vessel that is part of the generator, loading waste comprising steel into the heated vessel, melting the loaded waste to a molten state using a non-transferred torch to cut and melt the waste and then using a transferred torch to maintain a molten metal pool, adding additional steel to raise the molten metal pool to a minimum depth, raising the temperature to 2000 degrees Centigrade, acquiring EPA approval, loading waste into the vessel at a defined rate, maintaining the molten metal pool further melting any non-melted waste into a molten status with the transferred torch, determining BTU content and gas flow, injecting steam into the vessel, flowing gas from the vessel through scrubbers into storage containers and collecting the hydrogen in a collection vessel.

FIELD OF THE INVENTION

The present invention concerns a method for producing hydrogen using afuel gas generator system.

BACKGROUND OF THE INVENTION

The invention concerns a method for using a uniquely designed two-nozzleplasma generator which utilizes two plasma arc torches, anon-transferred torch and a transferred torch to create a molten poolfrom waste in a vessel, the introduction of steam into the vessel, andthe generation of hydrogen gas that ultimately runs steam boilers togenerate electricity.

This method can be used in particular for treatment of waste to obtainelectricity and for obtaining hydrogen gas. It can be used withmunicipal waste, tires medical waste and hazardous waste to generateelectricity.

Four-nozzle plasma generators are known. Methods to use them for cuttingand melting items are known. Four-nozzle plasma generators are typicallymade of two anode and two electrode chambers connected to a DC powersources. The four-nozzle plasma generators create plasma jets whoseshape and trajectory are typically dictated by an external magneticfield system. These types of plasma generators are known to be expensiveand a need has existed for a less expensive device that can also produceelectricity. A four-nozzle plasma generator is described in the documententitled Basis For Implementation Of The Method For Dynamic PlasmaTreatment Of The Surface Of A Solid Body, P. P. Koulik et al.,Plasmochimie 87″ Part 2, Moscow, 1987, pp. 58 to 96.

The construction of the electrode chambers (anode and cathode) for aplasma generator is described in the document entitled Twin JetPlasmatron, I. I. Genbaiev, V. S. Enguelsht, Frounze, 1983.

A need had existed for a low cost two-nozzle generator with a specificconfiguration enables efficient introduction of plasma to municipalwaste, or medical waste to melt the waste and ultimately producehydrogen gas.

A need has long existed for a generator that heats waste with plasmajets and, in the absence of cooled walls, offers high performance inoutput of hydrogen gas.

The generation of plasma jets and streams are often accompanied bytoroidal vortices. The resulting flow of hot gas heats parts of theelectrode chambers causes substantial heat losses by thus reducing thegenerator efficiency. On the other hand, when the degree of turbulenceof the plasma stream is increased, there is a loss of productsintroduced into the central zone of the stream generating harmfulsecondary effects in terms of the service life of the generator becausethese products precipitate on the surface of the electrode chambers andthe supply elements. Plasma radiation, which is particularly high whenchemical products are introduced into the plasma stream, is also a causeof superfluous heating of the various parts of the generator exposed tothis radiation. A need has existed from a stable, preferably portable orat least modular, generator that uses little or no water to treat wasteand generate usable product.

In addition to the generator itself, there is a need for a system andmethods to produce hydrogen. A need also has existed for efficientfeeding systems for the high-energy fuel gas generator.

SUMMARY OF THE INVENTION

The invention relates to method for producing hydrogen using a fuel gasgenerator system.

The generator of the method is a vessel having a front, a back, abottom, a first side, a second side, a third side, and a feed ramp. Afirst plasma arc torch known as a moveable non-transferred torch isdisposed in at least one side of the vessel for contacting waste that isfed into the chamber such as through an automatic feeding system. Withthe introduction and melting of the waste, particularly tires, a pool ofmolten material is formed. A second plasma arc torch is disposed behindand aligned with the first plasma arc torch, however the second torch isa moveable transferred torch and it is used for contacting the moltenmaterial and keeping it molten.

At least one steam injector is disposed in at least one side of thevessel for keeping molten material off the sides of the vessel and foradding water to the system. The introduction of water causes theformation of hydrogen gas by the plasma generators and through the heatof the molten pool. At least one molten material outlet is disposed inthe back of the vessel for removing molten material. At least one gasoutlet is disposed in the vessel for removing gas from the vessel tofirst a dry scrubber and then to a wet scrubber.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will be explained in greater detail with referenceto the appended figures, in which:

FIG. 1 is a side view of the generator;

FIG. 2 is a side view of the dry scrubber usable in the invention;

FIG. 3 is a side view of the non-transferred torch usable in theinvention;

FIG. 4 is a side view of the transferred torch; and

FIG. 5 is a top view of the vessel of the invention with 24 steaminjectors.

FIG. 6 is a top view of the feed system according to the invention in aposition where waste is about to be loaded into the chamber;

FIG. 7 is a top view of the feed system wherein waste has just beenexpelled from the chamber;

FIG. 8 is a top view of the container of the feed system with 6 inertgas injector ports;

FIG. 9 is a top view of the feed system having a controller;

FIG. 10 is a diagram of the method for start up of the generator from anelectrical power grid substation that is an independent power source;and

FIG. 11 is a diagram of the method for start up by the use of naturalgas and power from the generator of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Before explaining the present invention in detail, it is to beunderstood that the invention is not limited to the particularembodiments and that it can be practiced or carried out in various ways.

The method of the invention has as benefits, no fuel costs because themethod uses waste. It also has as a benefit, the reduction of wastegoing to landfills, including but not limited to tires and medicalwaste, including needles, and other material that is a mix of metal,hazardous waste and special waste as classified by the EPA.

The method of the invention has additional benefits, that of using aclosed vessel which, instead of “burning” the waste causing pollution,like an incinerator, instead does not cause any additional atmosphericpollution.

The present invention also has as a benefit a lower cost perkilowatt-hour produced because the source of the fuel for the generatoris lower than that for fossil fuels.

The present invention enables a generator to be running in 12 monthsrather than 5 to 7 years. And the method has the generator permittedquickly as a gasification unit.

Another benefit of the method is that no bottom ash or fly ash iscreated, no smoke stacks are used, no gassing off occurs as withtraditional electricity generation methods.

This method is very flexible because it can process any organic orinorganic compound and is less expensive to build than oil driventurbines because it can use recycled steam turbines to create theelectricity.

The invention is a method that uses a particular generator which isshown in more detail in FIG. 1 and FIG. 2, wherein the generator system(8) is shown having a vessel (10) with a front (12), a back (14), abottom (16), a first side (18) a second side (20) a third side (22) anda feed ramp (23) that communicates with a sealable opening (25).

The feed ramp is used to provide the waste material into the vessel,such as by rolling or by sliding into the container from a feed system.An optional feed system, such as an automatic feed system (24) could beused within the scope of the generator system.

The vessel (10) contains at least two plasma arc torches that are shownin more detail in FIGS. 3 and 4.

FIG. 3 shows the moveable non-transferred torch (28) that is disposed inat least one side of vessel (10) for contacting waste (26) and creatingmolten material (29).

FIG. 4 shows the second plasma arc torch that is disposed in vessel(10), wherein the second torch is termed a moveable transferred torch(30) and this torch is used for contacting the molten material (29). Thetwo plasma arc torches can be disposed in the same side or top of thevessel, or they could be disposed on opposite sides. Preferably eachtorch is pivotable and rotatable and swivel able. Additionally, in apreferred embodiment, the first torch points at the waste material as itgoes down the ramp and the second plasma arc torch points at the moltenpool created in the bottom of the vessel by the first torch, keeping thepool hot and further melting any additional waste which is not yetmelted.

Returning to FIG. 1 and FIG. 2, at least one steam injector (32) isdisposed in at least one side of vessel (10). In another embodiment, twosteam injectors are used, and as shown in a later FIG. 5, a vastplurality of steam injectors are used, which not only introduce waterand steam into the system to keep the molten material moving, butprovide a source of hydrogen, as attached to oxygen, which is separatedfrom the oxygen during the heating process. The generator of claim 1,wherein said steam injector (32) has an outer diameter between 1 inchand 6 inches. Note that FIG. 5 shows that between 4 and 24 steaminjectors can be used in the vessel, with 2-12 steam injectors beingdisposed on sides opposite each other.

At least one molten material outlet (34) is disposed in the back of thevessel (10) for removing molten steel, or other molten metal to formbars.

At least one gas outlet (36) is disposed in one side, such as the thirdside (22) of the vessel (10) (shown in FIG. 2, in particular) fortransferring gas from the vessel (10) to a dry scrubber (38). It iscontemplated that the dry scrubber has a dry scrubber outlet (42) forremoving treated gas.

The dry scrubber is connected to a wet scrubber (44) at the dry scrubberoutlet (42) for receiving gas from the dry scrubber, and furtherscrubbing the treated gas and passing the twice treated gas to a wetscrubber outlet (46).

It is also contemplated, as shown in FIG. 1, that the generator systemcan include a hydrocarbon injector (48) disposed in at least one side ofthe vessel for injecting into the waste: oil, other hydrocarbons sewage,sludge or combinations thereof, into the vessel for treatment along withthe waste.

FIG. 1 also shows an optional gas BTU enhancer port (66) for inputting aBTU enhancing material (68) to the vessel to increase the BTU ratings ofthe gas from the gas outlet. It is contemplated that the BTU enhancermaterial is a calcium carbonate material. Lime is also considered ausable BTU enhancer for this generator system.

Looking again at FIG. 2, it is shown that one embodiment contemplatesthat the dry scrubber (38) can further comprises a heat exchanger (40)for removing heat from the gas as it passes through the dry scrubber.Additionally shown in FIG. 2 is that the wet scrubber outlet (46) canoptimally be connected to a storage tank (70). Further optionalconsiderations include that the wet scrubber can be connected to a wetscrubber flare outlet (72) connected to a flare (74).

Once again returning to FIG. 1, it is shown that the generator systemcomprises an oxygen injector port (50) disposed in at least one side ofthe vessel for injecting oxygen into the vessel. The oxygen used in thisinjector point may be liquid oxygen or oxygen gas.

As to the specifics of the vessel design for the generator system, it iscontemplated that the feed ramp can have an angle of inclination between30-50 degrees between the feed system and the molten material, and morepreferably between 30-40 degrees, most preferably the angle ofinclination of the feed ramp is 40 degrees between the feed system andthe molten material.

It is also contemplated that the sides, front and bottom of the vesselare welded together. These components are contemplated to comprise a1-inch thick metal alloy. The metal alloy can comprise a member of thegroup: carbon steel and its alloys, stainless steel and its alloys,titanium and its alloys, and combinations thereof.

Overall, the vessel is contemplated to have a height between 12 feet and400 feet, and a length between 10 feet and 400 feet, and a width ofbetween 5 feet and 400 feet. More preferably, the generator has a heightbetween 12 feet and 18 feet, and a length between 10 feet and 30 feet,and a width of between 5 feet and 14 feet.

FIG. 3 provides details on the moveable non-transferred torch (28). Thistorch has an anode (52) and cathode (54) connected to a power supply(56) for creating an arc (58) to contact with the waste (26) in thevessel (10). The non-transferred torch is adapted to be rotatable to 180degrees, and adapted to be vertically moveable in the vessel.Preferably, the non-transferred torch is a 2-megawatt, water-cooledtorch. It is also contemplated that the non-transferred torch is furtheradapted to be moveable horizontally.

The power supply is contemplated to be a DC-power supply for the torch.

FIG. 4 shows the moveable transferred torch (30) has an transferredtorch anode (60) connected to a transferred torch power supply (62) forcreating a transferred torch arc (64) to contact with the moltenmaterial (29) in the vessel and the transferred torch is adapted to berotatable to 180 degrees, and adapted to be vertically moveable in thevessel. This transferred torch is contemplated to be a 2-megawatt,water-cooled torch. It is also contemplated that this transferred torchis further adapted to be moveable horizontally. The transferred torchpower supply could be a DC-power supply.

The waste treatable in the system can be a member from the EPA categoryof MUNICIPAL SOLID WASTE, SPECIAL WASTE comprising tires and medicalwaste or HAZARDOUS WASTE or combinations thereof.

The molten material for the generator is contemplated to be steel,carbon or combinations thereof. The molten material outlet (34)preferably has an outer diameter between 2 inches and 6 inches.

In one embodiment, the gas outlet has an outer diameter between 4 and 6inches and is externally cooled, such as water-cooled.

It is also contemplated that the vessel has at least five insulatingwalls disposed adjacent the sides of the vessel as shown in FIG. 1,elements (65), (67), (69), (71) and (73). These insulating wallspreferably comprise a non-stick refractory material, such as ruby brickrefractory material.

FIG. 5 shows the four to twenty-four steam injectors disposed in thevessel (76, 78, 80, 82, 84, 86, 88, 90, 92, 94, 96, 98, 100, 102, 104,106, 108, 110, 112, 114, 116, 118, 120, 122). The novel feed system forthis generator system of this invention is shown in more detail in FIG.6, FIG. 7, FIG. 8, and FIG. 9. The steam injectors can be between 1½feet and 3 feet above the molten metal pool.

In FIG. 6 and FIG. 7, the feed system has a sealable double walledcontainer (123) with an outer top side (124) and an inner top side(125). The outer top side (124) has a first rail (126) a second rail(128) and a door (130) for slidable engaging the first and second rails.The double walled container (123) has an outer first container side(132), an inner first container side (133), a outer second containerside (134), an inner second container side (135), an outer containerback (136), an inner container back (137), a outer container bottom(138), and an inner container bottom (139).

FIG. 6 and FIG. 7 also shows the container outer and inner backs furthereach have a hole disposed in them. The container outer back has an outerback hole (140). The container inner back has an inner back hole (141).The holes are aligned to permit a piston (142) to slide through theholed. The double wall container forms a space between one-half inch to2-inches connected to the vessel of the generator.

The piston (142) penetrates the holes (140) and (141), as shown in FIG.6 and FIG. 7. The piston is connected to a plate (144) on one end. Theplate slides in the container (122) forming a surface against which topush the waste bales or loose waste material. The piston (142) isconnected to the sealable opening locks to unlock all locks and to applypressure such that the plate can be retracted to a position against theback (136) revealing or essentially forming a loading chamber (148) topermit loading of waste (26) into the loading chamber.

At least two spring loaded door locks (143 and 145) connect to thetopside. Each door lock is adjacent to the door for locking the door ina closed position. At least two spring-loaded sealing locks (147 and149) are mounted on the vessel for locking the sealable opening, such asin a closed position.

A second piston (146) is connected to the door locks to unlock andretract the door for loading waste.

At least one inert gas injector (150) is mounted to at least one side orto the bottom of the container for flooding the loading chamber withinert gas, which assists in the movement of the gas and increases safetyof the system to prevent “back burning” of fire from the generator asthe waste is loaded into the chamber. This inert gas insertion techniqueinto the loading chamber of the automatic feeding system (24) (SeeFIG. 1) is a significant and key advantage of the system from a safetyand quick and efficient handling perspective.

Additionally, a liquid cooling system (152) is disposed in the spacecreated by the double walls of the container to keep the feeding systemcool and safe to work with for the operators and owner of the generator.

FIG. 8 shows the inert gas injectors (150, 154, 156, 158, 160, 162)disposed on the back (136) of the piston.

FIG. 9 shows the controller (164) that is used for operating the locks,door and sealable opening of the feeding system.

In a preferred embodiment, the liquid cooling system uses water as thecooling carrier.

In another preferred embodiment the feeding system can utilize at leastone pneumatic piston, or a hydraulic piston or a mechanical piston as atleast one of the pistons of the system. It is contemplated that acombination of these types of pistons could be used and controlled bythe controller (164).

In a preferred embodiment, it is contemplated that for the feed systemthe sealable opening of the vessel is a locking sliding door. The locksof the system, such as for the sliding door are contemplated as beinghydraulic locks and operable by the same controller (164) or by anindependent controller.

In still another embodiment, it is contemplated that the feed system thedoor and the sealable opening are hydraulically actuated.

For the gas injectors mounted in the container, it is contemplated thatat least two could be used, one on each side of the container and theinert gas that they inject could be nitrogen, argon, helium, carbondioxide or combinations thereof.

In still another embodiment of the feed system it is contemplated thatthe container top side, first rail, second rail, door, first containerside, second container side, container back, container bottom are allmade from an at least one-inch thick metal alloy, such as carbon steeland its alloys, stainless steel and its alloys, titanium and its alloys,or combinations thereof.

As to dimensions of the feed system, it is contemplated that the platehas dimensions of 30-inches by 50-inches by 60-inches and the plate hasa thickness between one-half inch and 2-inches. The plate could be madefrom a flame sprayed coating disposed on all sides of the plate, andthis coating could be a ceramic coating, such as one capable ofresisting heat up to 12,000 degrees Celsius. The piston is preferablyconnected to the plate at the center of the plate and the piston has anoverall length from between 10 and 400 feet. In one embodiment, thepiston is a solid rod.

As to size, the feed system container preferably has an outside heightbetween 12 feet and 400 feet, a length between 10 feet and 400 feet, anda width between 5 feet and 400 feet. More preferably the feed systemcontainer has a height between 12 feet and 18 feet, a length between 10feet and 30 feet, and a width of between 5 feet and 14 feet

It is contemplated that the waste for use in the feed system is eitherEPA category of MUNICIPAL SOLID WASTE, SPECIAL WASTE including tires andmedical waste, or HAZARDOUS WASTE.

It is contemplated that for the feed system the controller is a computerbased electro-mechanical device for controlling the pistons

The inventive method for converting waste into hydrogen using the plasmagenerator described above.

Referring to FIG. 10 the method involves the steps that start withobtaining scrap metal and inserting scrap metal into a vessel. Thefigure is representative of the method by showing the electricalsubstation (300), the power supply (310), the scrap metal (320), the gasgenerator (330), the steam source (340), the scrubber system (350), thegas storage tank (360), the steam boilers (370), the steam generators(380), and the flow to the power grid (390).

The next step shown in FIG. 10 is the pre-heating of the vessel usingelectricity from an electrical substation to a power supply that thenheat the vessel. The loaded waste comprising steel is melted in thevessel as it is heated. Preferably the loaded waste has steel, such assteel belted tires and the steel is cut by the plasma arc torch andmelted to a molten state in the vessel.

The method involves first using the non-transferred plasma arc torch tocut and melt the waste and then using the second transferred plasma arctorch to maintain the liquid state of the waste, creating a molten metalpool. Next, 4 tons of steel are added to the heated vessel creating amolten metal pool with a minimum operating depth

Next the heated vessel is heated further to an operating temperature ofat least 2000 degrees Centigrade.

EPA category MUNICIPAL SOLID WASTE, HAZARDOUS WASTE and/or SPECIAL WASTEis then load into the heated vessel. Preferably, the waste is loaded ata defined rate per hour.

Next the waste is transformed into molten material with thenon-transferred torch by cutting and heating.

After the first torch cuts and heats the molten material, the secondtorch maintains the molten material status of the waste by furthermelting any non-melted waste into a molten status

The next step involves determining BTU content and gas flow from thegenerator using conventional test techniques.

Following the testing for BTU content, steam is injected into the vesselfrom a steam source. Gas, hydrogen gas, is then flowed from the vesselthrough the scrubber system shown in FIG. 10. The scrubber systemconsists of first a dry scrubber and then a wet scrubber. Afterscrubbing the gas is passed into gas storage tanks or similar storagecontainers. Gas is then passed from the storage containers to at leastone steam boiler. The hydrogen is used to heat the steam boiler toproduce steam to run at least one steam generator or steam turbine togenerate electricity at a capacity up to 50 megawatts. Up to 6 steamturbines and 6 steam boilers are contemplated as usable in this method.The power generated from the steam generators is then passed out tosources needing power, such as a power grid.

It is noted that a preferred embodiment of this method involves loadingwaste into the vessel at a rate of 4 bales per hour, with each bale ofwaste weighing 2000 pounds.

In another embodiment, it is contemplated that prior to heating thevessel, four tons of steel are loaded into the vessel to create aminimum operating depth of molten material.

In an embodiment of the invention it is contemplated that waste isloaded in bales of 2000 pounds per hour. When bales are used, it iscontemplated that the first plasma arc torch of the vessel cuts thebales and transforms the waste into molten material.

The inventive method contemplates that the BTU content and gas flow datais determined by taking gas samples.

In the most preferred embodiment, gas is passed from the vessel throughthe dry and wet scrubbers and into storage containers at a rate of 90000cubic feet per 2000 pounds of waste.

A second embodiment of the start up method is shown in FIG. 11. In thismethod, the scrap metal is loaded in the vessel as in the method of FIG.10. FIG. 11 represents the method by showing the power supply (310), thescrap metal (320), the gas generator (330), the scrubber system (350),the gas storage tank (360), the steam boilers (370), the flow thenatural gas supply (375), the steam generators (380), the flow to thepower grid (390), and the flow of the back feed to the power supply(395).

The vessel is heated from a power supply. The generator produces thenecessary gas in the method described above and the gas is scrubbed in ascrubber system. The gas is then flowed to gas storage tanks and to asteam boiler. The steam boiler can be initially started up using anatural gas supply to produce power. The steam from the boilers is thensent to the steam generators to create power. The power is then fed outto the grid and to the power supply for additional start up or forsupplying power to the plasma arc torches to keep the method, cheap,using recycled materials, and some power produced by the process.

The invention also includes a hydrogen storage vessel connected to thewet scrubber outlet. The hydrogen storage vessel collects the hydrogengas produced from the invention's method.

While this invention has been described with emphasis on the preferredembodiments, it should be understood that within the scope of theappended claims, the invention might be practiced other than asspecifically described herein.

1. A method for producing hydrogen using a generator a. wherein thegenerator comprises i. a vessel having a front side, a back side, bottomside, a first side, a second side, a third side, and a feed ramp; ii. afeed system with a sealable opening disposed in the front for supplyingwaste to the vessel; iii. a moveable non-transferred torch disposed inat least one side of said vessel for contacting said waste creatingmolten material; iv. a moveable transferred torch for contacting themolten material wherein the transferred torch is disposed in at leastone side of said vessel; v. at least one steam ‘injector disposed in atleast one side of said vessel; vi. at least one molten material outletdisposed in the back of said vessel; vii. at least one gas outletdisposed in the third side of the vessel for transferring gas from thevessel to a dry scrubber wherein said dry scrubber further has a dryscrubber outlet; viii. a wet scrubber connected to the dry scrubberoutlet for receiving gas from the dry scrubber, and further scrubbingsaid gas and passing said gas to a wet scrubber outlet; ix. a hydrogenstorage vessel connected to the wet scrubber outlet; b. heating thevessel; c. loading waste comprising steel into the heated vessel; d.melting the loaded waste comprising steel to a molten state in thevessel by first using a non-transferred torch to cut and melt the wasteand then using a second transferred torch to maintain the liquid stateof the waste creating a molten metal pool; e. adding an additional 4tons of steel to the heated vessel creating a molten metal pool with aminimum operating depth; f. raising the heated vessel temperature to anoperating temperature of at least 2000 degrees Centigrade; g. acquiringEPA category MUNICIPAL SOLID WASTE, HAZARDOUS WASTE and/or SPECIAL WASTEto load into the vessel; h. loading said waste into the vessel at adefined rate per hour; i. transforming the waste into molten materialwith the non-transferred torch by cutting and heating said waste; j.maintaining the molten material status of the waste by further meltingany non-melted waste into a molten status with the transferred torch; k.determining BTU content and gas flow; l. injecting steam into thevessel; m. flowing gas from the vessel through the dry and wet scrubbersand into storage containers; and n. collecting the gas in the hydrogenstorage vessel.
 2. The method of claim 1, wherein waste is loaded intothe vessel at a rate of 8000 pounds per hour.
 3. The method of claim 1,wherein, at start-up, four tons of steel are loaded into the vessel tocreate a molten metal pool with a minimum operating depth.
 4. The methodof claim 1, wherein the waste is loaded in bales of 2000 pounds at arate of 4 bales per hour and the first torch of the vessel cuts thebales and transforms the waste into molten material.
 5. The method ofclaim 1, wherein said BTU content and gas flow data is determined bytaking gas samples.
 6. The method of claim 1, wherein gas is flowed fromthe vessel through the dry and wet scrubbers and into storage containersat a rate of 90000 cubic feet per 2000 pounds of waste.
 7. The method ofclaim 1, wherein the steam injectors are between 1-½ feet and 3 feetabove the molten metal pool.